VOLVO D16E

The Power of Volvo in Construction Equipment

Volvo is a major manufacturer of diesel engines and is the worlds
largest producer of heavy-duty diesel engines in the 9 to 18 liter size
bracket.

A new air management system incorporating a unique, patented,

switchable I-EGR system, a new standard turbocharger and a new air-to-air
charge air cooler;

Volvo diesel engines are powering the trucks, buses and construction
equipment produced by the company and is a major power source in
marine and industrial applications.

An enhanced electronic controller for precise control of the fuel and air
handling systems.

We presented our first internal combustion engine in 1893. Ever since,

we have been in the forefront of engine technology and performance.
The new generation Volvo heavy-duty diesel engines featuring V-ACT
(Volvo Advanced Combustion Technology) for off-road applications is
further proof of Volvos high level of engine technology and of the
companys solid experience to successfully apply innovative solutions to
well-proven Volvo engine designs and to optimize the integration of engine
and equipment for maximum machine performance and productivity.

Volvo D16E diesel engine in

Volvo construction equipment
The Volvo D16E is Volvos most powerful diesel engine with a
power-range that in its various on- and off-road applications spans
from 346 kW (471 hp) to 604 kW (821 hp).
The design of the Volvo D16E is based on a solid evolution of the
world-leading diesel engine technology introduced in the Volvo
D12, the worlds most manufactured diesel engine in the 12-liter
size class, and represents a new generation of high performancelow emission Volvo diesel engines.
The Volvo D16E has many design features in common also with
the 9 liter Volvo D9B, such as the configuration and location of the
timing mechanism.
Featuring Volvos advanced electronic engine management system
another shared element and a major V-ACT feature used with all
six-cylinder medium and large size Volvo diesel engines for offroad applications that instantaneously adapts performance to suit
each new operating situation.

The new-generation Volvo diesel engines with V-ACT provide, in an

uncomplicated manner, high engine efficiency and output, optimized fuel
economy, maintained performance and lower emissions in compliance with US
(EPA) Tier 3 / EU Stage IIIA exhaust emission requirements for non-road
machinery. With V-ACT, no external devices or after-treatment of the exhaust
gases are required for Tier 3 / Stage IIIA compliance.

Engine performance matching the

application optimized performance of
each Volvo diesel engine model for
operation in each individual model of
Volvo construction equipment.
Volvo as one of just a few
manufacturers of both engines and
construction equipment enjoy the
benefits of an entirely integrated
equipment/engine system, creating an
optimized match between engine,
machine systems and operator controls.

Volvo Construction Equipment is different. The companys

products are designed, built and supported in a different way.
That difference comes from our 175-year engineering heritage.
A heritage of thinking first about the people who actually use
the machines. About how to make them safer, more comfortable,
more productive. About the environment we all share. The result
of that thinking is a growing range of machines and a global
support network dedicated to helping you do more. People
around the world are proud to use Volvo. And were proud of
what makes Volvo different More care. Built in.

The resulting main benefits are:

Power when and where needed
Torque as needed, with peak
torque at low to modest engine
speeds
Ample torque rise as required by
application

Configured for the demanding heavy-duty applications in

construction, earthmoving and mining equipment.

Smooth, direct throttle response

for maximum operability and
maximum operator satisfaction and
efficienty

Providing outstanding performance, reliability and durability.

Low fuel consumption

Manufactured with world-leading engine production and assembly

technology.

Low exhaust emission levels

Complies with US (EPA) Tier 3 and EU Stage IIIA exhaust

emission standards.

VOLVO D16E DIESEL ENGINE

WITH V-ACT

A new flexible, high-pressure fuel injection system with latest-generation

unit injectors;

As one of the leading diesel engine manufacturers in the world, Volvo

possesses extensive, advanced engine research & development and
manufacturing resources.

You will find Volvo diesel engines at work all over the world, in all
climates and conditions.

VOLVO CONSTRUCTION EQUIPMENT

V-ACT is the acronym for Volvo Advanced Combustion Technology. It embodies

the unique technology specifically developed by Volvo for its heavy- and
medium-duty diesel engines that power Volvo construction equipment. V-ACT
represents new achievements in the areas of combustion efficiency, emissions
reduction and overall engine performance.
Major V-ACT features include:

Low noise levels

All products are not available in all markets. Under our policy
of continuous improvement, we reserve the right to change
specifications and design without prior notice. The illustrations
do not necessarily show the standard version of the machine.

MORE CARE. BUILT IN.

Ref. No. 22 A 100 3523
Printed in USA 2007.07 2

English

US (EPA) TIER 3 / EU STAGE IIIA

For many years, Volvo has been one of the world leaders in heavy-duty
diesel engine development. All Volvo heavy-duty diesel engines share
the same basic state-of-the-art technology. The result unprecedented
confidence in the best engines in the world for your business.

20
3

NUMBER OF UNITS PRODUCED

One-piece cylinder head of cast iron, providing

stable bearings for the overhead camshaft for
precise valve actuation. The cylinder head features
an intermediate deck that promotes sturdiness and
enhances cooling. The inlet and outlet ports are
optimized for low pressure drop. There is one
common fuel channel to the injectors. The cylinder
head gasket is of steel, with integrated rubber seals
for water and oil ports, providing heat resistance
and durability.
Induction-hardened, overhead camshaft with
seven bearing trestles and removable bearing
shells. The camshaft is provided with carefully
shaped lobes for valve control and with a cam
profile adapted to the unit injectors. The exhaust
rocker arm has a switchable double rocker device,
an unique feature instrumental to Volvos patented
I-EGR solution (see paragraph on I-EGR below).
An extra rocker arm is fitted in parallel to the
exhaust rocker arm; simply put, one rocker arm for
the ordinary exhaust lift event and one for the
I-EGR activation.

High pressure, flexible fuel injection system with

centrally located, camshaft-driven, electronicallycontrolled, dual solenoid unit injectors for precise
fuel injection timing, optimum pressure and exact
fuel quantity required in each instance.
The unit injectors are vertically installed for optimal
distribution of the fuel in the combustion chamber.

10

Sturdy cylinder block, made of cast iron and

provided with wet, replaceable cylinder liners.
To withstand the very high firing pressures of the
modern diesel engine, the sides of the block have
a curved shape at the level of each cylinder in
order to produce high stiffness and good sound
reduction.
A ladder frame, consisting of a sturdy steel plate,
is bolted onto the bottom of the block for extra
rigidity and durability.

SPECIFICATIONS
The new heavy-duty, Tier-3/StageIIIA-compliant Volvo D16E featuring
V-ACT, is a 16.1 liter, in-line, four-stroke, water-cooled, six-cylinder diesel
engine with turbo and intercooler. It features an integrated single cylinder head,
four valves per cylinder, overhead camshaft, electronically-controlled unit
injectors and Volvos enhanced electronic engine management system, EMS-2.

Displacement

The pistons, made of steel, are provided with jet

spray oil cooling (cavity cooling) for uniform piston
temperature. The oil cooling also encompasses the
piston ring zone and the combustion chamber, all
contributing to sustained efficient combustion and
lower oil consumption. There are two compression
rings and one oil ring. The connecting rod is of
forged steel.

Base engine configuration

Valve mechanism with four-valve technology

cross-flow configuration of the inlet and
exhaust ports for efficient gas flow
fully symmetrical combustion chamber
enhances air/fuel swirl control for highly
efficient combustion
replaceable alloy steel valve guides and steel
valve seats
all valve guides have oil seals for low oil
consumption

11

Drop-forged, inductionhardened crankshaft,

provided with a
vibration damper of the
viscous type.

21

The flywheel is secured to the crankshaft by

through-bolts in a large diameter bolt pattern for
strength and durability. The flywheel ring gear is
replaceable. The generous radius of the flywheel
serrations allows high accuracy of engine speed
sensoring for maximum fuel injector control and
performance.

18

The engine timing gear train is fitted on a

sturdy steel plate that is bolted on to the rear
end of the cylinder block. It incorporates a
hydraulic damper on the camshaft gear for
minimized vibrations and noise.
The rear end location of the timing gear means
fewer moving parts and contributes to a very
high precision of valve motion and injection
timing, and to a virtually vibration-free running of
the engine and a reduced sound level.

12

The enhanced engine cooling system,

including a new type of radiator provides
effective heat dissipation which, together with the
electronically-controlled cooling fan (except
excavators) for minimized energy losses,
contributes to the engines high efficiency rating.
Inside the engine, calibrated cooling ducts
interact to provide balanced cooling. The coolant
flow is distributed between the cylinder liners
upper and lower coolant jackets and the cylinder
head. A coolant thermostat is integrated in the
cylinder head.

13

14

Turbocharged/air-to-air

Bore

144 mm

4.75 in.

Stroke

165 mm

5.4 in.

Cam/valve configuration

SOHC/4 valves per cylinder

12

Torque
895 ft.lbs. 1254 ft.lbs.
2420 Nm 2550 Nm

For specific engine output data by product application, see machine brochures.
Information presented in this guide is current at time of printing.

EPG (Exhaust Pressure Governor)/ Engine

brake. Exclusive, patented Volvo technology for use
on Volvo trucks, buses and articulated haulers. An
efficient exhaust retarder fitted on the turbochargers
exhaust outlet restricts the exhaust gas flow, thus
increasing engine backpressure which results in a
braking effect. A pulse width modulated (PWM)
control valve allows variable control of the EPG for
variable braking effect. Extra braking power at no
extra cost.
Main PTO (power take-off) integrated in the
flywheel housing (artic.haulers). Specifically
designed for the high output requirements of the
articulated hauler application. Engine side-mounted
PTO available as required by application.
Force-fed lubrication system ensures sufficient oil
supply, also at cold starts.

16

The efficient oil cooler, integrated in the cylinder

block, assures full oil temperature control. An oil
cooler bypass valve ensures lubrication of the engine
at cold starts.

17
Power
346 kW 397 kW
471 hp 540 hp

Switchable I-EGR (Internal Exhaust Gas

Recirculation) system.
Exhaust emissions reduction achieved by the application
of the patented double rocker device, an integral
element of V-ACT, whereby at high engine speeds and
loads a controlled portion of exhaust gases is fed back
into the cylinder during the inlet stroke by a short, second
exhaust valve lift event. (see 2 lower left)
The I-EGR system is electronically-controlled by the EMS
based on machine and engine operating conditions.

15

Power and torque range

(in Volvo construction equipment,
at varying engine speeds
depending on applications)

183000

DaimlerChrysler

170000

Oil filtration system

Two full-flow and one bypass oil filter for maximum
filtration efficiency, long change intervals and engine
reliability and durability. The filters are either enginemounted or chassis-mounted and are strategically
located in order to enhance serviceability.

Inlet air filtration system in three steps for efficient,

reliable air cleaning, low maintenance costs and longer
service life
pre-cleaner
main filter with replaceable insert
safety filter

146000

Weichai Power

134000

Cummins
Scania
MAN
KamAZ

72000
67000
52000

The chart reflects production of diesel engines in 2006 in the 9-18 liter size class.

Oil-bath filter, fitted in series with and ahead of the dry

type filters, is optional (for particularly severe operating
conditions).

12

18.1:1

19

10

The oil sump is designed in order to ensure

reliable oil supply in non-road operations. A
rubber gasket is positioned in a groove in the
sump. The sump is fastened to the cylinder
block by means of spring-loaded bolts; this
constitutes a tight seal and reduces noise.

200000

Volvo

Caterpillar

Other Significant Features

Four cycle/inline six cylinder

Compression ratio

13

11

16.1 liter

Aspiration/intercooler

16

Sensors
A number of engine parameters are continuosly
sensed for precision control of engine performance.
(For further details, see separate EMS box).

14
17
18

19

20

15

The fuel filtration system, more efficient in view of

additional requirements on fuel cleanliness stemming
from the new fuel injection system, consists of a 10
micron pre-filter, including a water separator with a
sensor that monitors the level of condensate, and a main
5 micron filter for maximum protection of the fuel injection
system. A new type of fuel filter housing, with automatic
air bleeding, incorporates non-return valves in the filter
nipples which prevent leakage at fuel filter exhange. A
fuel tank breather filter is an additional feature.

The air-to-air intercooler, specifically designed for

demanding non-road applications, cools the inlet air by up
to 150 degrees C ( 300 degrees F), for increased fuel
efficiency and reduced exhaust emissions, nitrogen oxides
(NOx) in particular. The colder air also reduces stresses on
valves and pistons for extended engine service life.
High-capacity batteries and starter motor, tested in cold
climates for reliability of operation.
An engine pre-heater warms the air in the inlet manifold
to assure fast, gentle cold starts at ambient temperatures
as low as 25 deg. C ( 15 deg. F). Its activation duration
is regulated by the coolant temperature.
Electric transmission of the throttle application provides
precise throttle control.

State-of-the-art Computer Aided Design (CAD) plays an essential role in

the engineering of the Volvo diesel engines and also, as these Volvo D16E
CAD creations show, in facilitating the engineering work required to
optimally install the engine and its ancillaries into the machine.

A turbocharger of the standard fixed-geometry type

for simplicity and reliability features improved flow
characteristics and higher charge air pressure
capability. Enhances engine efficiency and contributes
to lower emission levels. In order to cope with the high
turbo speeds and to achieve the required efficiency,
the specially designed compressor wheel is milled
from a solid, forged piece of high strength aluminum.
Total Electronic Control and Diagnostics
The E-ECU controls combustion to optimize output and
minimize fuel consumption and emissions. The system
also eliminates the risk of engine shock loads and
protects the engine from over-speeding. A malfunction is
immediately indicated in the Contronic monitoring system.
At engine start-up, the electronic system automatically
diagnoses all machine functions, including the engine.
A separate, Volvo-unique PC-based diagnostic tool,
VCADS Pro, is used by the Volvo service technician for
in-depth performance analysis, fault-tracing, diagnostics
and programming, if necessary.
In addition, the engines (and the machines) operational
history, including engine speed and fuel consumption
data, is registered and stored, and can be retrieved from
the electronic control system for analysis.

FEATURES

BENEFITS

Performance
High efficiency
Ample power and torque
Excellent low end torque
High torque across a wide engine speed range
with peak torque at modest engine speed
Fast engine response
One engine, different layouts
Optimum engine/equipment matchperformance
characteristics optimally adapted and fine-tuned
to the requirements of each application

High Productivity

Reliability and Durability; Availability

A proven Volvo base engine with the highest
quality of material and constituent parts,
manufactured to the most exacting standards
Constant electronic control and monitoring of
the operation of the engine for optimal
performance
Effective and highly reliable air, fuel and
lubrication systems, including very efficient
filtering systems
Powerful diagnostic tool (VCADS Pro)
for quick fault analysis. Service of the engine
greatly facilitated
CareTrack telematic remote machine tracking and
operating control system, including engine
monitoring

High operational availability

Productivity

High availability; productivity

Enhanced availability
Maximum operational control and
up-time

Operator efficiency and convenience

Excellent engine response
power and torque when and where
needed for the application
high performance also at low engine speeds
ample torque rise as required by application
Smooth, precise throttle control
Low noise and vibration levels

Sustained high productivity and

competitive fuel economy

Convenience and comfort

Convenience and comfort

Low operating costs

Electronic control of the combustion process
and high thermal efficiency rating
Simplified service and maintenance work
and long service intervals
oil change at 500 hour intervals
(normal operating conditions)
filters regrouped for ease of service
and maintenance
easy access to engine installation for
service and maintenance

21

Competitive fuel economy

Low maintenance and service costs

Environmental Care
Enhanced, latest-generation EMS (Engine Management System),
EMS 2, whereby the E-ECU (Engine Electronic Control Unit) is
integrated with the machines other electronic control units to
form a highly efficient, interactive, real-time electronic
communication system for optimum engine/machine performance,
whatever the application and operating conditions. 21

CAD representation of overhead camshaft and

valve actuation mechanism

Low exhaust emissions

meets current exhaust emission legislation
(US Tier 3/EU Stage IIIA)
Low noise levels
Fuel filter housing anti-spill non-return valves
and anti-spill oil drainage device

Tier 3/Stage IIIA-compliance

Minimum impact on the environment

Minimum impact on the environment